Wiring system for interconnecting vehicle-mounted electronic devices through a wiring harness

ABSTRACT

A wiring system is provided where at least one device connector and at least one device connector are interconnected. The wiring system has at least one main harness with at least one group of wires aligned in a substantially parallel direction, and at least one sub harness with at least one group of wires forming at least one wire crossover. A coupling structure is further provided to couple the main and sub harnesses together to form a complete wiring harness that extends between the first and second device connectors. The wire crossover is provided only in the sub harness, so that the main harness is free of any wire crossovers.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a wiring system for interconnectingvehicle-mounted electronic devices via a wiring harness and, inparticular, to an improvement in the wiring system where a routingconfiguration of the wiring harness is simplified.

2. Description of Related Art

FIG. 5 shows a first example of a conventional wiring system thatincludes a vehicle-mounted device such as an electronic control unit(ECU) 1 for an electronic fuel injection (EFI) system. The ECU 1 hasthree ECU connectors A, B, C for connection to connectors a, b, c thatare attached to leading ends W1, W2, W3 of an electric wire group W.However, wires of the electric wire group W, which are connected to theconnectors a, b, c at one end, are configured to be dispersedlyconnected to different connectors e, f, g, h at the other end. In otherwords, wires that are equally connected to one connector at one end aredispersedly connected to different connectors at other ends. This isbecause an input signal is sent to the ECU through one wire, and anoutput signal is sent from the ECU through another wire.

As shown in FIG. 6, wires of an electric wire group W1 are connected tothe connector a at one end, and are dispersedly connected to fourdifferent connectors e, f, g, h at other ends during subassembly. Wiresof electric wire groups W2, W3 have the same configuration, except thatthey are not connected to the connectors e, f, g, h at the other endduring subassembly.

More particularly, all the electric wire groups W1, W2, W3 arerespectively connected to the connectors a, b, c at one end in advanceduring subassembly. However, only the electric wire group W1 isconnected to the connectors e, f, g, h at other end during subassembly.The remaining electric wire groups W2, W3 are manually coupled to theconnectors e, f, g, h subsequently, during final assembly. Arrows shownin FIG. 6 indicate terminals which are crimped at the other ends of thewires of the wire groups W2, W3 and which are mounted in the connectorse, f, g, h subsequently during final assembly. The wires are lefthanging, and the terminals are left exposed until final assembly.

This presents the following problems, especially when the wires are longlike the ones that are connected to the ECU 1 and that measureapproximately 2000 mm-3000 mm.

When other ends of long wires are left scattered and hanging withoutbeing connected to connectors, the overall assembly is tedious andcumbersome to assemble, and exposed terminals at the other ends of thelong wires are susceptible to damage. Also, it is difficult to insertthe exposed terminals into a connector during final assembly becausethey are attached to the long wires.

Also, FIG. 7 (A) shows a second example of a conventional wiring system.A wiring harness W/H-1, produced by bundling a plurality of wires d,extends between devices K1, K2 to electrically connect them viaconnectors C1, C2 provided at opposite ends thereof. Connectionterminals (not shown) are provided at connection areas K1 a, K2 a of thedevices K1, K2. The respective connection terminals are independentlyand uniquely arranged so that the arrangement patterns of the connectionterminals do not correspond to one another between the connection areasK1 a, K2 a. Thus, the wiring harness W/H-1 has wire crossovers, with thewires d intersecting with one another.

This makes the lengths of the wires d different. Thus, the wires d haveto be measured and cut separately one by one, as shown in FIG. 7(B).After the wires d are measured and cut, terminals are attached toopposite ends of the wires d, and then inserted into predeterminedcavities of the connectors C1, C2.

As described above, manufacturing the wiring harness W/H-1 as shown inFIG. 7(A) requires a very cumbersome and time-consuming process, whichdoes not allow manufacturing costs to be reduced.

Additionally, FIG. 8 shows a third example of a conventional wiringsystem that includes a wiring harness W/H-2 produced by bundling aplurality of wires d. The wiring harness W/H-2 extends among devices K3,K4, K5 and switches SW1, SW2, and electrically connect them viaconnectors C3, C4, C5, C6, C7 provided at respective ends thereof. Thedevices K3, K4, K5 and switches SW1, SW2 share common circuits, so thatjoint connectors J1, J2 are provided to form joint portions S1, S2 inthe wiring harness W/H-2.

Since these joint portions S1, S2 are required, an overall circuitconfiguration of the wiring harness W/H-2 is complicated and cumbersome.As a result, time-consuming, subsequent terminal insertion rate duringfinal assembly increases, thereby decreasing efficiency in subassemblyand thus deteriorating the merits of subassembly production. Further, itis difficult to introduce an automatic assembly machine that wouldimprove assembly efficiency because of the cumbersome circuitconfiguration. Furthermore, as in the case of the wiring harness W/H-1as shown in FIG. 7(A), the wires d of the wiring harness W/H-2 mayintersect to form crossovers, depending on the requirements ofconnection terminals arranged at connection areas of the devices K3, K4,K5 and switches SW, SW2. This further complicates the problems of thiswiring system.

SUMMARY OF THE INVENTION

The present invention has been developed after taking the above problemsinto consideration, and an object thereof is to provide a wiring systemwhich ensures an easy connection between electronic devices through awiring harness. Another object of the present invention is to simplifyand make efficient the wiring harness manufacturing process itself.

The present invention provides a wiring system for interconnecting atleast first and second device connectors of an electronic control unitand at least first and second external connectors associated with atleast one electronic device. The electronic device is spaced apart fromthe electronic control unit. The first and second device connectors areconstructed of a predetermined first terminal arrangement pattern, andthe first and second external connectors are constructed of apredetermined second terminal arrangement pattern. The predeterminedfirst and second terminal arrangement patterns do not correspond to eachother.

The wiring system has at least first and second long, main harnesses.Each of the main harnesses has at least one electric wire terminatedwith an end terminal at one end thereof and a relay terminal at theother end thereof. The end terminal is inserted in an end connector, andthe relay terminal is inserted in a relay connector. The end connectorsof the first and second main harnesses are configured for connection tothe first and second external connectors.

The wiring system further has at least first and second, short subharnesses. Each of the sub harnesses has at least one electric wireterminated with an end terminal at one end thereof and a relay terminalat the other end thereof. The end terminal is inserted in an endconnector, and the relay terminal is inserted in a relay connector. Theend connectors of the first and second sub harnesses are configured forconnection to the first and second device connectors. The relayconnectors of the first and second sub harnesses are configured forconnection to the relay connectors of the first and second mainharnesses, so that at least first and second wiring harnesses are formedwhen the relay connectors of the first and second sub harnesses and thefirst and second main harnesses are coupled together.

The relay connectors of the first and second sub harnesses, the relayconnectors of the first and second main harnesses and the end connectorsof the first and second main harnesses are constructed of apredetermined terminal arrangement pattern that corresponds to thepredetermined second terminal arrangement pattern of the first andsecond external connectors. Accordingly, the wire of the first mainharness and the wire of the second main harness extend withoutintersecting with each other. Hence, the end and relay terminals of thefirst and second main harnesses can be mounted in the end and relayconnectors of the first and second main harnesses respectively duringsubassembly, and thus the first and second main harnesses can besub-assembled independently of each other.

The end connectors of the first and second sub harnesses are constructedof a predetermined terminal arrangement pattern which corresponds to thepredetermined first terminal arrangement pattern of the first and seconddevice connectors. The predetermined first terminal arrangement patterndoes not correspond to the predetermined second terminal arrangementpattern of the first and second external connectors. Thus, the wire ofthe first sub harness and the wire of the second sub harness extend,intersecting with each other. Hence, the first and second sub harnessescannot be assembled independently of each other during subassembly.

The above construction of the present invention is particularlyeffective for use in an automotive wiring system where a plurality ofcomposite wiring harnesses are routed to a plurality of deviceconnectors provided at an electronic control unit for an electronic fuelinjection system. More particularly, the composite wiring harnessesextend from the electronic control unit to at least one connector of ajunction box, at least one connector of a fuse box and/or at least oneconnector attached to other wiring harness(es) extending to otherelectronic device(es).

According to the above construction, only the end terminals (or therelay terminals) of the first and second sub harnesses can be insertedin their corresponding connectors during subassembly. The remainingrelay terminals (or the end terminals) are inserted subsequently duringfinal assembly, and are left hanging and exposed until final assembly.

However, the first and second long, main harnesses are left free of anysubsequent terminal insertion operations. Thus, the wires of the firstand second main harnesses can be automatically crimped to the end andrelay terminals, then the end and relay terminals can be automaticallymounted in the end and relay connectors.

Even though the subsequent terminal insertion operation is carried outon the first and second sub harnesses, these sub harnesses are veryshort in length. Consequently, the wires of these sub harnesses areunlikely to become entangled, and thus are easy to handle.

In a preferred form of the present invention, the first and second subharnesses each constitute approximately 5% to 10% of a total length ofthe first and second wiring harnesses, respectively. More preferably,the first and second sub harnesses each constitute approximately 5% ofthe total length. Still more preferably, the wires of the first andsecond main harnesses each measure approximately 2000 mm-3000 mm and thewires of the first and second sub harnesses measure approximately 100mm.

Further, the present invention provides a wiring system forinterconnecting at least one device connector of at least one firstelectronic device and at least one second device connector of at leastone second electronic device spaced apart from the first electronicdevice.

The wiring system has at least one main harness with at least one groupof wires aligned in a substantially parallel direction, and at least onesub harness with at least one group of wires. The group of wires of thesub harness has at least one wire crossover formed therein. The wiringsystem further has a coupling structure configured to couple the mainand sub harnesses together to form a complete wiring harness thatextends to interconnect the first and second device connectors. The wirecrossover is formed only in the sub harness, with the main harness freeof any wire crossovers.

In accordance with the above construction, the wiring harness is dividedin a plane perpendicular to an extending direction thereof, in order toform the sub harness and the main harness. The wire crossover isconcentrated in the sub harness, so that the main harness is left freeof any wire crossovers. Accordingly, the wires of the main harness canbe measured and cut collectively at the same time, thereby reducingmanufacturing time, as opposed to the conventional manufacturing methodof measuring and cutting the wires of a wiring harness separately one byone.

In the event where one end of the main harness is attached to aninsulation displacement type connector, the main harness can, forexample, be manufactured by:

-   -   (a) measuring the wires collectively at the same time;    -   (b) mounting leading ends of the wires in pressure contact with        a first end connector collectively at the same time, thereby        providing the first end connector for connection to the first        device connector at one end of the main harness;    -   (c) cutting the other ends of the wires collectively at the same        time; and    -   (d) crimping the other ends of the wires to terminal fittings,        and mounting the terminal fittings in a second end connector,        thereby providing the second end connector for connection to an        end connector of the sub harness at the other end of the main        harness.

In this manner, the main harness can be manufactured efficiently. Thus,the wiring harness is preferably divided, such that the main harnessoccupies a major portion of a total length of the wiring harness, e.g.,90%-95% of the total length.

Even though the sub harness has the wire crossover, the sub harness isminiaturized, and thus the wires of the sub harness are very short inlength. Therefore, the manufacturing of the sub harness (i.e., separatewire measuring and cutting operation and separate terminal crimping andinsertion operation) is not so time-consuming, as compared to the caseof the conventional wiring harness. As a result, the overallproductivity can be improved significantly.

In another aspect of the present invention, the coupling structure has amain harness side connector and a sub harness side connector which aremutually engageable with each other. A plurality of electrical terminalsare arranged in the main harness side and sub harness side connectorsrespectively in such a manner as:

-   -   (a) to correspond to an electrical terminal arrangement pattern        of the first device connector, so that the wires of the main        harness are aligned in a substantially parallel manner; and    -   (b) not to correspond to an electrical terminal arrangement        pattern of the second device connector, so that the wires of the        sub harness are not aligned in a substantially parallel manner.

Preferably, the main harness has at least one end connector forconnection to the first device connector, with a plurality of electricalterminals arranged in the end connector in such a manner as tocorrespond to the electrical terminal arrangement pattern of the firstdevice connector.

Furthermore, the present invention provides a wiring system forinterconnecting at least one device connector of at least one firstelectronic device and at least one second device connector of at leastone second electronic device.

The wiring system has at least one main harness with at least one groupof wires aligned in a substantially parallel direction, and at least onesub harness having at least one group of wires with at least one jointportion provided therein.

The wiring system further has a coupling structure configured to couplethe main and sub harnesses together to form a complete wiring harnessthat extends to interconnect the first and second device connectors. Thejoint portion is provided only in the sub harness, with the main harnessfree of any joint portions.

In accordance with the above construction, the wiring harness is dividedto form the sub harness with the joint portion concentrated therein andthe main harness without any joint portions provided therein.Accordingly, the same advantages as described above can be achieved.

In a preferred form, the wires of the sub harness are also aligned in asubstantially parallel direction.

Still further, the present invention provides a wiring system forinterconnecting at least first and second device connectors provided ina first electronic device and at least first and second externalconnectors associated with at least one second electronic device spacedapart from the first electronic device.

The wiring system has at least first and second main harnesses eachhaving at least one group of wires aligned in a substantially paralleldirection, and at least first and second sub harnesses each having atleast one group of wires.

The wiring system further has at least first and second coupling membersconfigured to couple the first and second main harnesses and the firstand second sub harnesses together respectively, to form at least firstand second wiring harnesses that extend to interconnect the first andsecond device connectors and the first and second external connectors.

The wires of the first and second sub harnesses are configured to extenddispersedly between the first and second device connectors and the firstand second coupling members, so that at least one wire crossover isformed, with at least one of the wires of the first sub harnessintersecting with at least one of the wires of the second sub harness.As a result, the main harnesses are left free of any wire crossovers.

In a further aspect of the present invention, the first and second mainharnesses are provided with first and second end connectorsrespectively. A predetermined terminal arrangement pattern of the firstand second coupling members and the first and second end connectorscorresponds to an electrical terminal arrangement pattern of the firstand second external connectors, respectively. Hence, the wires of thefirst and main harness are aligned in a substantially parallel manner.

In another aspect of the present invention, a composite wire harness isprovided that includes a main harness including only a plurality offirst wires, with all of the first wires aligned substantially parallelwith one another, a sub harness including a plurality of second wires,with at least one of the second wires being a crossover wire, and aconnecting device configured to connect the main harness to the subharness to form the composite wire harness.

The sub harness is substantially shorter than the main harness, and thesub harness may have a length of approximately 5% to 10% of the lengthof the composite wire harness. Also, the first wires may have a lengthof approximately 2000 mm to 3000 m, and the second wires have a lengthof approximately 100 mm.

In a further aspect of the present invention, the connecting device ofthe composite wire harness may include a main harness side connector anda sub harness side connector which are mutually engageable with eachother, and a plurality of electrical terminals are arranged in the mainharness side and sub harness side connectors respectively in such amanner as:

-   -   (a) to correspond to an electrical terminal arrangement pattern        of a first device connector so that the first wires of the main        harness remain aligned in a substantially parallel manner; and    -   (b) not to correspond to an electrical terminal arrangement        pattern of a second device connector so that the second wires of        the sub harness are not aligned in a substantially parallel        manner.

Additionally, the main harness may include at least one end connectorfor connection to the first device connector, and a plurality ofelectrical terminals are arranged in the end connector in such a manneras to correspond to the electrical terminal arrangement pattern of thefirst device connector.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features of the invention will be apparent from the followingdescription of preferred embodiments shown by way of example only in theaccompanying drawings in which:

FIG. 1 is a schematic view illustrating a wiring system according to afirst embodiment of the present invention;

FIG. 2(A) is a schematic view illustrating a wiring system according toa second embodiment of the present invention;

FIG. 2(B) is an exploded view of a wiring harness according to thesecond embodiment of the present invention;

FIG. 3(A) is a schematic view illustrating a manufacturing process of amain harness of the wiring harness according to the second embodiment ofthe present invention;

FIG. 3(B) is a schematic view illustrating a variation of themanufacturing process of the main harness according to the secondembodiment of the present invention

FIG. 4 (A) is a schematic view illustrating a wiring system according toa third embodiment of the present invention;

FIG. 4(B) is an exploded view of a wiring harness according to the thirdembodiment of the present invention;

FIG. 5 is a schematic view of the first example of a conventional wiringsystem;

FIG. 6 is a view illustrating how a conventional wiring harnessaccording to the first example is assembled from subassemblies;

FIG. 7(A) is a schematic view illustrating the second example of aconventional wiring system;

FIG. 7(B) is a view how a conventional wiring harness according to thesecond example is manufactured;

FIG. 8 is a schematic view illustrating the third example of aconventional wiring system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The embodiments of the present invention will be described withreference to the drawings.

FIG. 1 shows the first embodiment of the present invention. The firstembodiment is particularly applicable in a wiring system where one ormore wiring harnesses are connected to a plurality of connectorsprovided in a vehicle-mounted device such as the ECU 1 for the EFIsystem, as in the case shown in FIG. 5.

Main harnesses W/H4, W/H5, W/H6 are respectively sub-assembled byconnecting connectors e, f, g, h to leading ends of electric wire groupsW4, W5, W6, W7, and by connecting main connectors i, j, k to the otherends of the electric wire groups W4, W5, W6, W7.

The length of these electric wire groups W4, W5, W6, W7 is L1, where L1is preferably approximately 2000 mm-3000 mm, which is about 95% of apredetermined total length from ECU connectors A, B, C provided in theECU 1 to the connectors e, f, g, h provided at the leading ends of themain harness W/H4, W/H5, W/H6.

The main (long) harnesses W/H4, W/H5, W/H6 have a length correspondingto L1 and are configured so that all the electric wire groups W4, W5,W6, W7 can be terminated to the connectors e, f, g, h, i, j, k atopposite ends thereof during subassembly. Thus, automatic termination ofthe ends of the electric wire groups W4, W5, W6, W7 is possible.

Sub (short) harnesses W/H1, W/H2, W/H3 extend between the mainconnectors i, j, k and the ECU connectors A, B, C. The length of thesesub harnesses W/H1, W/H2, W/H3 is L2 where L2 is preferablyapproximately 100 mm, which is about 5% of the total length. Of course,L1 and L2 may have any suitable dimension where L1 remains greater thanL2. However, it is preferred that L1 constitute 90% to 95% of the totallength, with L2 constituting the remaining 5% to 10%.

Connectors a, b, c for connection to the ECU connectors A, B, C areprovided at ends of electric wire groups W1′, W2′, W3′ of the subharnesses W/H1, W/H2, W/H3, as in the case in FIG. 5.

In the electric wire group W1′ of the sub-harnesses W/H1, a terminalterminated to the other end of a wire W1′-1 is fitted in a sub-connectorm during subassembly, while terminals terminated to the other ends ofthe remaining wires W1′-2 are fitted in sub-connectors n, psubsequently. Likewise, in the electric wire group W2′ of the subharnesses W/H2, a terminal terminated to the other end of a wire W2′-1is fitted in the sub-connector n during subassembly, while terminalsterminated to the other ends of the remaining wires W2′-2 are fitted inthe sub-connectors m, p subsequently. Similarly, in the electric wiregroup W3′ of the sub harnesses W/H3, a terminal terminated to the otherend of a wire W3′-1 is fitted in the sub-connector p during subassembly,while terminals terminated to the other ends of the remaining wiresW3′-2 are fitted in the connectors m, n subsequently.

In this manner, all the subsequent terminal insertion operations arecarried out only on the sub-harnesses W/H1, W/H2, W/H3. Accordingly, allthe electric wire groups W4, W5, W6, W7 of the main harnesses W/H4,W/H5, W/H 6 can be terminated to the connectors e, f, g, h, i, j, k atopposite ends thereof during subassembly.

The main harness W/H4 is connected to a fuse block (not shown), and themain harness W/H5 is connected to a junction block (not shown). The mainharness W/H6 is connected to an output-side wiring harness (not shown).

As described above, the wiring harnesses W/H1; W/H3, W/H2; W/H5, W/H4;W/H6 are respectively divided in a plane perpendicular to an extendingdirection thereof to form the long main harnesses W/H4, W/H5, W/H6 andthe short sub-harnesses W/H1, W/H2, W/H3. The long main harnesses W/H4,W/H5, W/H6 can be completely terminated to the connectors e, f, g h, i,j, k at opposite ends thereof during subassembly, and thus can be formedinto complete subassemblies. Hence, the electric wire groups W4, W5, W6,W7 of the main harnesses W/H4, W/H5, W/H6 can be automatically connectedto the connectors e, f, g, h, i, j, k.

Also, since all the subsequent terminal insertion operations are carriedout on the sub-harnesses W/H1, W/H2, W/H3 that are short in length, theoperations are easy to carry out, and the wires W1′-2, W2′-2, W′3-2 areunlikely to become scattered and entangled during final assembly. Inaddition, the sub-harnesses W/H1, W/H2, W/H3 that are connected to theECU 1 can be of standard configuration and can be commonly applicable tothose for use in different types of vehicles, while the main harnessesW/H4, W/H5, W/H6, which may vary in configuration according to differenttypes of vehicles, can be sub-assembled completely. Thus, the overallwiring harness productivity is significantly improved.

FIGS. 2(A) and (B) show the second embodiment of the present inventionin which devices K1, K2 are connected via a wiring harness W/H-10, as inthe case in FIG. 7(A). The wiring harness W/H-10 is divided in a planeperpendicular to an extending direction thereof to form a main harnessH-11 and a sub harness H-12. The main harness H-11 occupies the majorityof the length of the wiring harness W/H-10, while the sub harness H-12occupies the remaining minority of the length. Since the terminalarrangement patterns of connection terminals (not shown) provided atconnection areas K1 a, K2 a of the devices K1, K2 do not correspond toone another, it is necessary to extend wires d between the devices K1,K2, while forming crossovers, with the wires d intersecting with oneanother. However, the crossovers are provided only at the sub-harnessH-12, so that the main harness H-11 is left free of any crossovers.Thus, the wires d constituting the main harness H-11 are aligned in asubstantially parallel direction.

The main harness H-11 has a connector C12 for connection to the deviceK2 at one end H-11 a thereof and a connector C13 for connection to thesub harness H-12 at the other end H-11 b thereof. Also, the sub harnessH-12 has a connector C11 for connection to the device K1 at one end H-12a thereof and a connector C14 for connection to the main harness H-11 atthe other end H-12 b thereof.

FIG. 3(A) shows a manufacturing process of the main harness H-11. Thewires d of the main harness H-11 have the same length in the absence ofthe crossovers. Thus, all the wires d are measured and cut collectivelyat the same time. Thereafter, terminals are crimped to both ends of thewires d, and inserted into the connectors C12, C13. In this way,production of the main harness H-11 is very efficient, and is lesstime-consuming and cumbersome.

FIG. 3(B) shows a manufacturing process of a variation of the mainharness H-11 which includes an insulation displacement type connectorC12′. The wires d of a main harness H-11′ have the same length in theabsence of the crossovers. Thus, all the wires d are measuredcollectively at the same time, and the ends H-12 a of all the wires dare mounted in pressure contact with the insulation displacement typeconnector C12′ collectively at the same time. Subsequently, the otherends H-12 b are cut collectively at the same time, and crimped toterminal fittings. Then, the terminal fittings are mounted in theconnector C13. In this way, production of the main harness H-11′ is veryefficient, and is less time-consuming and cumbersome. Thus, an automaticassembling machine can be introduced to various production processes toimprove the overall productivity.

The manufacturing process of the sub harness H-12 is similar to that ofthe conventional wiring harness W/H-1 as shown in FIG. 7(B). However,the sub harness H-12 itself is short in length in an axial direction,and thus is miniaturized. Therefore, burdens of measuring and cuttingwires separately one by one; crimping terminal fittings to the wires;and inserting the terminal fittings in the connectors are significantlyreduced. Thus, manufacturing time is reduced significantly, as comparedto the conventional construction.

According to the second embodiment of the present invention, although itis necessary to manufacture both the main harness H-11 and the subharness H-12, each of them can be manufactured efficiently. Thus, atotal manufacturing time of the main and sub harnesses H-11, H-12 isshorter than that of the wiring harness W/H-1.

The main and sub harnesses H-11, H-12 thus constructed are connected viathe connectors C13, C14, thereby completing the wiring harness W/H-10.The wiring harness W/H-10 is connected to the devices K1, K2 via theconnectors C11, C12 to electrically interconnect the devices K1, K2.

In the second embodiment, a wiring harness is configured to interconnecttwo devices. However, it is equally applicable in the case where thewiring harness extends to connect more than two devices. Also, in theevent that the terminal arrangement pattern provided at a connectionarea of one device does not match that of another device considerably, awiring harness can be divided at a plurality of locations to form aplurality of sub harnesses and main harnesses.

FIGS. 4(A) and (B) show the third embodiment of the present invention. Awiring harness W/H-20 produced by bundling a plurality of wires d isprovided to connect a plurality of devices K3, K4, K5 and switches SW1,SW2, as in the case shown in FIG. 8. The wiring harness W/H-20 isdivided at two places to form a main harness H-21, a first sub harnessH-22 and a second sub harness H-23.

Since the devices K3, K4, K5 and switches SW1, SW2 share commoncircuits, it is necessary to form joint portions S21, S22, S23 in thewiring harness W/H-20. However, the joint portion S21 is formed in thefirst sub harness H-22, and the joint portions S22, S23 are formed inthe second sub harness H-23, so that the main harness H-21 is left freeof any joint portions, thereby aligning the wires d thereof in asubstantially parallel direction. In addition, the wiring harness W/H-20is divided so that the main harness H-21 occupies a major portion of thewiring harness W/H-20 and the sub harnesses H-22, H-23 occupy a minorportion.

The main harness H-21 has connectors C21, C22 at opposite ends H21 a,H-21 b thereof. The first sub harness H-22 has a connector C28 whichmates with the connector C21 at one end H-22 a thereof, and connectorsC23, C24 for connection to the devices K3, K4 at the other ends thereof.Further, the second sub harness H-23 has a connector C29 which mateswith the connector C22 at one end H-23 a thereof, and connectors C25,C26, C27 for connection to the device K and the switches SW1, SW2 at theother ends thereof.

The main harness H-21 is manufactured efficiently in a similar manner asthe main harness H-1 of the second embodiment, i.e., by measuring andcutting the wires d collectively at the same time and aligning the wiresd in a substantially parallel direction, without any joint portionsformed thereon, thereby eliminating the cumbersome manufacturingprocess. Of course, an automatic assembling machine may be used tomanufacture the main harness H-21.

The first and second sub harnesses H-22, H-23 are also manufactured in asimilar manner as the conventional wiring harness W/H-2 as shown in FIG.8. However, the sub harnesses H-22, H-23 form complete subassemblies assingle members, which allows an early stage terminal insertion rateduring subassembly and wire-laying operation efficiency (or subassemblyefficiency) to increase, thereby improving productivity. Also, since thelength of each wire is considerably shorter than that used in the wiringharness W/H-2, it is very easy to measure and cut wires, crimp terminalfittings to the wires, then mount the terminals in a connector housing,thereby reducing manufacturing time. The joint portions S21, S22, S23are constructed of joint connectors J21, J22, J23 in the same manner asthe conventional joint portions shown in FIG. 8. The number of jointportions increases by one, as compared to the conventional embodimentshown in FIG. 8. However, since the increased joint portion S23 isabsorbed in the miniaturized, second sub harness H-23, the overallproductivity does not deteriorate.

Even though the wiring harness W/H-20 is composed of a total of threeharness, i.e.; the main harness H-21 and the first and second subharnesses H-22, H-23, assembly inefficiency for each harness issignificantly reduced, thereby making the total manufacturing time tomanufacture these three harnesses less than it takes to manufacture theconventional wiring harness W/H-2 shown in FIG. 8.

An assembly of the wiring harness W/H-20 is completed when the connectorC21 provided at one end of the main harness H-21 is coupled to theconnector 28 of the first sub harness H-22, and the connector C22provided at the other end of the main harness H-21 is coupled to theconnector C29 of the second sub harness H-23. The wiring harness W/H-20thus completed is connected to the devices K3, K4, K5 and the switchedSW1, SW2 via the connectors C23, C24, 25, C26, C27 to form apredetermined electrical circuit.

A wiring harness according to the third embodiment is applicable in bothof the cases where it extends from one device to another device andwhere it extends from one device to a plurality of devices. Also, Awiring harness according to the third embodiment is configured to absorbcrossovers in sub harnesses, so that wires of a main harness are alignedin a substantially parallel direction. Additionally, its scope shouldnot be limited to dividing a wiring harness at two locations; the wiringharness may be divided at one location or at more than one locationaccording to required circuit configurations.

Further, it is preferable that a wiring harness according to the thirdembodiment be introduced, in particular, to a module such as aninstrument panel module that connects devices in and/ or around aninstrument panel. For example, a main harness can be connected to aninstrument panel trunk harness, and sub harnesses can be connected to anaccessory module and a switch module, respectively.

As is clear from the above description of the preferred embodiments, oneor more wiring harnesses are divided in a plane perpendicular to anextending direction thereof, in order to form one or more long mainharnesses and one or more short sub harnesses. The main harnesses areconfigured so that they can be completely sub-assembled duringsubassembly, free of any subsequent terminal insertion operations. Thus,it is possible to automatically terminate electric wire groups of themain harnesses to connectors, thereby improving productivity.

The subsequent terminal insertion operations are carried out only on thesub harnesses that are very short in length. As a result, the wires ofthe sub harnesses are unlikely to become scattered and entangled duringsubassembly, and thus are easy to handle. Further, it is advantageous inthat such a short and thereby productive sub harnesses can be commonlyshared among different types of vehicles as device connection harnesses.

Further, a wiring harness that includes wire crossovers is divided toform a main harness for aligning wires in a substantially paralleldirection and at least one sub harness for absorbing the crossovers.Thus, manufacturing time and effort can be reduced, thereby improvingproductivity significantly. In addition, a wiring harness that includesjoint portions is divided to form a main harness for aligning wires in asubstantially parallel direction and a sub harness for absorbing thejoint portions. Thus, manufacturing efficiency can be improved, and anoverall wiring harness configuration can be simplified by concentratingcumbersome portions such as the joint portions in the sub harness.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to certain embodiments, it is understood that the wordswhich have been used herein are words of description and illustration,rather than words of limitation. Changes may be made, within the purviewof the appended claims, as presently stated and as amended, withoutdeparting from the scope and spirit of the present invention in itsaspects.

Although the present invention has been described herein with referenceto particular means, materials and embodiments, the present invention isnot intended to be limited to the particulars disclosed herein. Rather,the present invention extends to all functionally equivalent structures,methods and uses, such as are within the scope of the appended claims.

The present disclosure relates to subject matter contained in priorityJapanese Applications No. Tokugan 2001-013853, filed on Jan. 22, 2001and No. 2001-259396, filed on Aug. 29, 2001 which are herein expresslyincorporated by reference in its entirety.

1. A wiring system for interconnecting at least first and second deviceconnectors of an electronic control unit and at least first and secondexternal connectors associated with at least one electronic devicespaced apart from the electronic control unit, the first and seconddevice connectors having a predetermined first terminal arrangementpattern, the first and second external connectors having a predeterminedsecond terminal arrangement pattern which does not correspond to thepredetermined first terminal arrangement pattern, the wiring systemcomprising: at least first and second long, main harnesses each havingat least one wire terminated with an end terminal at one end thereof andwith a relay terminal at the other end thereof, the end terminal beinginserted in an end connector and the relay terminal being inserted in arelay connector, the end connectors of the first and second mainharnesses being configured for connection to the first and secondexternal connectors; at least first and second, short sub harnesses eachhaving at least one wire terminated with an end terminal at one endthereof and with a relay terminal at the other end thereof, the endterminal being inserted in an end connector and the relay terminal beinginserted in a relay connector, the end connectors of the first andsecond sub harnesses being configured for connection to the first andsecond device connectors, the relay connectors of the first and secondsub harnesses being configured for connection to the relay connectors ofthe first and second main harnesses, so that at least first and secondwiring harnesses are formed when the relay connectors of the first andsecond sub harnesses and the relay connectors of the first and secondmain harnesses are coupled together; wherein the relay connectors of thefirst and second sub harnesses, the relay connectors and the endconnectors of the first and second main harnesses include apredetermined terminal arrangement pattern that is configured tocorrespond to the predetermined second terminal arrangement pattern ofthe first and second external connectors, so that the wire of the firstmain harness and the wire of the second main harness extend withoutintersecting with each other, whereby the end and relay terminals of thefirst and second main harnesses can be mounted in the end and relayconnectors of the first and second main harnesses respectively duringsubassembly, and whereby the first and second main harnesses can besub-assembled independently of each other; and wherein the endconnectors of the first and second sub harnesses include a predeterminedterminal arrangement pattern that is configured to correspond to thepredetermined first terminal arrangement pattern of the first and seconddevice connectors which does not correspond to the predetermined secondterminal arrangement pattern of the first and second externalconnectors, so that the wire of the first sub harness and the wire ofthe second sub harness extend, intersecting with each other, whereby thefirst and second sub harnesses cannot be sub-assembled independently ofeach other.
 2. The wiring system of claim 1, wherein the first andsecond sub harnesses each constitute approximately 5% to 10% of a totallength of the first and second wiring harnesses, respectively.
 3. Thewiring system of claim 2, wherein the wires of the first and second mainharnesses measure approximately 2000 mm-3000 mm and the wires of thefirst and second sub harnesses measure approximately 100 mm.